U.S. patent number 9,375,893 [Application Number 14/212,640] was granted by the patent office on 2016-06-28 for automotive panels.
This patent grant is currently assigned to BASF SE. The grantee listed for this patent is BASF SE. Invention is credited to Garry Balthes, Brad Joseph Martin, Karl Richard Nicholas.
United States Patent |
9,375,893 |
Nicholas , et al. |
June 28, 2016 |
Automotive panels
Abstract
A panel construction suitable for automotive parts comprises (a)
a first composite fiber mat layer (b) adjacent to and covering a
face of the fiber mat, a thermoplastic polymer film and optionally
(c) adjacent to and covering the thermoplastic film, a second
composite fiber mat layer, where the fiber mats comprise non-woven
fibers or fabrics and a cured acrylic resin binder. The
thermoplastic film is preferably a thermoplastic polyurethane film.
The construction preferably contains no adhesive layer between
components (a), (b) and (c).
Inventors: |
Nicholas; Karl Richard (Aurora,
IL), Balthes; Garry (Elkhart, IN), Martin; Brad
Joseph (Dearborn, MI) |
Applicant: |
Name |
City |
State |
Country |
Type |
BASF SE |
Ludwigshafen |
N/A |
DE |
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Assignee: |
BASF SE (Ludwigshafen,
DE)
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Family
ID: |
51528378 |
Appl.
No.: |
14/212,640 |
Filed: |
March 14, 2014 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20140272400 A1 |
Sep 18, 2014 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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61783066 |
Mar 14, 2013 |
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61787108 |
Mar 15, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B
27/06 (20130101); B32B 7/02 (20130101); B32B
5/08 (20130101); B32B 5/24 (20130101); B32B
19/02 (20130101); B32B 5/022 (20130101); B32B
23/02 (20130101); B32B 27/32 (20130101); B32B
7/08 (20130101); B32B 27/12 (20130101); B32B
27/304 (20130101); B32B 27/36 (20130101); B32B
19/04 (20130101); B32B 19/045 (20130101); B32B
5/06 (20130101); B32B 5/10 (20130101); B32B
7/04 (20130101); B32B 7/05 (20190101); B32B
27/308 (20130101); B32B 23/08 (20130101); B32B
23/04 (20130101); B32B 27/20 (20130101); B32B
27/40 (20130101); B32B 27/285 (20130101); B32B
27/288 (20130101); B32B 2307/3065 (20130101); Y10T
428/266 (20150115); Y10T 428/31565 (20150401); Y10T
428/269 (20150115); B32B 2605/00 (20130101) |
Current International
Class: |
B32B
5/08 (20060101); B32B 7/08 (20060101); B32B
19/02 (20060101); B32B 19/04 (20060101); B32B
23/02 (20060101); B32B 23/04 (20060101); B32B
23/08 (20060101); B32B 5/06 (20060101); B32B
5/02 (20060101); B32B 27/06 (20060101); B32B
27/40 (20060101); B32B 27/36 (20060101); B32B
27/32 (20060101); B32B 27/30 (20060101); B32B
27/28 (20060101); B32B 27/20 (20060101); B32B
27/12 (20060101); B32B 5/10 (20060101); B32B
5/24 (20060101); B32B 7/02 (20060101); B32B
7/04 (20060101) |
Field of
Search: |
;428/361,375,423.7,424.2 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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201291619 |
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Aug 2009 |
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CN |
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29607085 |
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Jun 1996 |
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DE |
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10250023 |
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May 2004 |
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DE |
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0184768 |
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Jun 1986 |
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EP |
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2408012 |
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May 2005 |
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GB |
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Other References
International Search Report and Written Opinion issued in
International Application No. PCT/US2014/028854, dated Jul. 2,
2014. cited by applicant .
International Search Report issued in International Application No.
PCT/IB2014/001574 on Oct. 28, 2014. cited by applicant.
|
Primary Examiner: Tran; Thao T
Attorney, Agent or Firm: Meunier Carlin & Curfman
LLC
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority to U.S. Provisional
Patent Application No. 61/783,066 filed Mar. 14, 2013, and also
claims the benefit of priority to U.S. Provisional Patent
Application No. 61/787,108 filed Mar. 15, 2013, both of which are
incorporated by reference herein in their entirety.
Claims
What is claimed is:
1. A panel construction suitable as an automobile part, comprising:
(a) a first composite fiber mat layer and (b) adjacent to and
covering a face of the first composite fiber mat layer, a
thermoplastic polymer film, wherein the first composite fiber mat
layer comprises fibers or fabrics and a cured acrylic resin binder,
wherein the thermoplastic polymer film penetrates the first
composite fiber mat layer, and wherein the thermoplastic polymer
film is substantially completely within the surface of the first
fiber mat, and the acrylic resin is from about 20% to about 40% by
weight of dried resin, based on the finished weight of the first
composite fiber mat layer.
2. The panel construction according to claim 1, wherein the
thermoplastic polymer film is a polyvinylchloride, polyethylene,
polyester, polyetheretherketone, or a polyurethane film.
3. The panel construction according to claim 1, wherein the
thermoplastic polymer film is a thermoplastic polyurethane
film.
4. The panel construction according to claim 1, wherein the first
composite fiber mat layer comprises non-woven cellulosic bast
fibers, non-woven polyester fibers or glass fibers.
5. The panel construction according to claim 1, wherein the
thermoplastic polymer film comprises one or more additives selected
from the group consisting of pigments, dyes, flame retardants,
hindered amine light stabilizers, ultraviolet light absorbers, and
anti-static agents.
6. The panel construction according to claim 1, wherein the
thermoplastic polymer film in total is from about 1 mil to about 12
mils thick.
7. The panel construction according to claim 1, further comprising
a second composite fiber mat adjacent to and covering the
thermoplastic film.
8. The panel construction according to claim 7, which is a
three-layer system comprising components (a), (b), and (c).
9. The panel construction according to claim 7, wherein the first
and second composite fiber mat layers are from about 1.5 to about 2
mm thick.
10. The panel construction according to claim 8, which construction
contains no adhesive layers between components (a), (b) and
(c).
11. The panel construction according to claim 8, wherein the first
and second composite fiber mat layers are identical.
12. The panel construction according to claim 8, wherein the first
and second composite fiber mat layers are not identical.
13. An automotive part comprising the panel construction of claim
1.
14. The automotive part according to claim 13, wherein the
automotive part is a lower sound shield, acoustical belly pan, aero
shield, splash shield, underbody panel, chassis shield, or a wheel
well liner.
Description
FIELD
The present disclosure is aimed at lightweight, strong, and durable
automotive panels, in particular underbody shields.
BACKGROUND
Automobile makers are currently looking for strong, lightweight
materials for automotive parts. Replacing existing metal parts with
more lightweight parts will reduce fuel consumption.
SUMMARY
Accordingly, disclosed is a panel construction suitable as an
automobile part, which comprises:
(a) a first composite fiber mat layer and
(b) adjacent to and covering a face of the fiber mat, a
thermoplastic polymer film and optionally
(c) adjacent to and covering the thermoplastic film, a second
composite fiber mat layer,
where the composite fiber mats comprise fibers or fabrics and a
cured acrylic resin binder.
DETAILED DESCRIPTION
Disclosed is a panel construction suitable as an automobile part,
which comprises:
(a) a first composite fiber mat layer and
(b) adjacent to and covering a face of the fiber mat, a
thermoplastic polymer film and optionally
(c) adjacent to and covering the thermoplastic film, a second
composite fiber mat layer,
where the composite fiber mats comprise fibers or fabrics and a
cured acrylic resin binder.
The panel construction comprises a 2 layer system of fiber mat and
thermoplastic polymer film or a 3 layer system. The 3 layer system
contains a thermoplastic polymer film in between two fiber mat
layers.
The fiber mats comprise non-woven fibers or fabric, woven fabrics
or non-crimp fabrics and a cured thermoset acrylic binder.
Preferably, the fiber mats comprise non-woven fibers.
The fibers are natural, synthetic or glass fibers. Synthetic fibers
are for instance carbon fibers or polyester fibers. Natural fibers
are for instance cellulosic bast fibers. The non-woven fibers may
contain a small amount synthetic thermoplastic fiber, for instance
polyethylene terephthalate fibers (PET). The fibers may be
synthetic polyester fibers or other fibers of similar
characteristics. The fibers are chosen to sustain all environmental
conditions.
The acrylic binder is a cured aqueous based acrylic resin. The
binder cures for instance through the carboxylic groups and a
multi-functional alcohol.
Acrylic binders are polymers or copolymers containing units of
acrylic acid, methacrylic acid, their esters or related
derivatives.
The acrylic binders are for instance formed by aqueous emulsion
polymerization employing (meth)acrylic acid (where the convention
(meth)acrylic is intended to embrace both acrylic and methacrylic),
2-hydroxyethyl(meth)acrylate, 2-hydroxypropyl(meth)acrylate,
2-hydroxybutyl(meth)acrylate, methyl(meth)acrylate,
ethyl(meth)acrylate, propyl(meth)acrylate, isopropyl(meth)acrylate,
butyl(meth)acrylate, amyl(meth)acrylate, isobutyl(meth)acrylate,
t-butyl(meth)acrylate, pentyl(meth)acrylate, isoamyl(meth)acrylate,
hexyl(meth)acrylate, heptyl(meth)acrylate, octyl(meth)acrylate,
isooctyl(meth)acrylate, 2-ethylhexyl(meth)acrylate,
nonyl(meth)acrylate, decyl(meth)acrylate, isodecyl(meth)acrylate,
undecyl(meth)acrylate, dodecyl(meth)acrylate, lauryl(meth)acrylate,
octadecyl(meth)acrylate, stearyl(meth)acrylate,
tetrahydrofurfuryl(meth)acrylate, butoxyethyl(meth)acrylate,
ethoxydiethylene glycol (meth)acrylate, benzyl(meth)acrylate,
cyclohexyl(meth)acrylate, phenoxyethyl(meth)acrylate, polyethylene
glycol mono(meth)acrylate, polypropylene glycol mono(meth)acrylate,
methoxyethylene glycol (meth)acrylate,
ethoxyethoxyethyl(meth)acrylate, methoxypolyethylene glycol
(meth)acrylate, methoxypolypropylene glycol (meth)acrylate,
dicyclopentadiene(meth)acrylate, dicyclopentanyl(meth)acrylate,
tricyclodecanyl(meth)acrylate, isobornyl(meth)acrylate,
bornyl(meth)acrylate or mixtures thereof.
Other monomers which can be co-polymerized with the (meth)acrylic
monomers, generally in a minor amount, include styrene,
diacetone(meth)acrylamide, isobutoxymethyl(meth)acrylamide,
N-vinylpyrrolidone, N-vinylcaprolactam,
N,N-dimethyl(meth)acrylamide, t-octyl(meth)acrylamide,
N,N-diethyl(meth)acrylamide,
N,N'-dimethyl-aminopropyl(meth)acrylamide,
(meth)acryloylmorphorine; vinyl ethers such as hydroxybutyl vinyl
ether, lauryl vinyl ether, cetyl vinyl ether, and 2-ethylhexyl
vinyl ether; maleic acid esters; fumaric acid esters and similar
compounds.
Multi-functional alcohols are for instance hydroquinone,
4,4'-dihydroxydiphenyl, 2,2-bis(4-hydroxyphenyl)propane, cresols or
alkylene polyols containing 2 to 12 carbon atoms, including
ethylene glycol, 1,2- or 1,3-propanediol, 1,2-, 1,3- or
1,4-butanediol, pentanediol, hexanediol, octanediol, dodecanediol,
diethylene glycol, triethylene glycol, 1,3-cyclopentanediol, 1,2-,
1,3- or 1,4-cyclohexanediol, 1,4-dihydroxymethylcyclohexane,
glycerol, tris(.beta.-hydroxyethyl)amine, trimethylolethane,
trimethylolpropane, pentaerythritol, dipentaerythritol,
tripentaerythritol and sorbitol.
The aqueous based acrylic binders are commercially available under
the ACRODUR name from BASF.
The aqueous based acrylic resin is infused in the fiber mat. That
is to say, the fiber mat is impregnated with the acrylic resin. The
fiber mats are compressed and cured with heat and pressure.
Pressure is not required for curing, but for setting a desired
thickness or density or shape.
Forming takes place for instance in a heated, shaped tool to a
desired shape.
The aqueous based acrylic binder may be applied to the non-woven
fibers or fabrics either through a dip-and-squeeze method, a
curtain coater or a foam injection method. The mixture is dried to
a low moisture content (about 4% to 7% by weight) prior to thermal
curing. This is the fiber mat prepreg.
During initial heating and compression, compression release allows
moisture to vent. The number of releases depends on the amount of
moisture contained in the un-cured mat. The cured fiber mat does
not contain significant amounts of water, for instance from 0% to
about 3% or from about 0.1 percent to about 2% by weight, based on
the dry weight.
Once cured, the fiber mat does not significantly swell.
A typical mat basis weight is from about 100 grams/square meter
(gsm) to about 1400 grams/square meter. The acrylic resin loading
is from about 15% to about 50%, preferably from about 20% to about
40% by weight, of dried resin based on the finished mat weight.
A typical fiber mat is generally about 1 cm thick prior to curing.
Once pressed and cured, the fiber mat is generally from about 1.5
to about 2 mm thick.
In the 3 layer system, the two fiber mats may be identical or
different. They may be of the same basis weight or thickness or be
of different basis weight or thickness. The fibers employed in the
two fiber mats of the 3 layer system may be the same or
different.
The term "panel constructions" means shaped parts. Fastening
features may be designed within the structures to improve the
process of assembly and reduce air and water ingress.
The thermoplastic film may comprise any suitable plastic, for
instance the thermoplastic film is a polyvinylchloride (PVC),
polyethylene, polyester, polyetheretherketone (PEEK) or a
polyurethane film. The thermoplastic polymer film is preferably a
thermoplastic polyurethane (TPU) film.
Thermoplastic polyurethane resin is well known and is commercially
available for instance under the trade names ELASTOLLAN (BASF) and
DESMOPAN (Bayer).
Commercially available TPU resin is generally based on either
polyester or polyether polyol and either aromatic or aliphatic
isocyanate. Preferably, the present TPU is aliphatic-based, that
is, based on aliphatic isocyanate compounds, which provides for
superior weather resistance.
The present thermoplastic film is applied to the outside face of
the fiber mat for instance in a molten form. The film may penetrate
the pores of the fiber mat and mechanically bond thereto. The
remaining portion of the film creates a durable surface.
Alternatively, the thermoplastic film may reside up to 80%, 90% or
substantially completely within the surface of the fiber mat.
Conveniently, the thermoplastic film resin may be mixed with
plastics additives such as pigments, dyes, flame retardants,
hindered amine light stabilizers, ultraviolet light (UV) absorbers,
anti-static agents and the like. Pigments are advantageously added
to the thermoplastic resin to provide the film with a desired
color. The pigments may be conventional pigments or effect
pigments. Flame retardants and hindered amine light stabilizers are
also advantageously added to the thermoplastic resin. Suitable
ultraviolet light stabilizers are for instance selected from
hydroxyphenylbenzotriazoles and hydroxyphenyl-s-triazines. The
ultraviolet light absorbers (UVAs) and hindered amine light
stabilizers (HALS) are well known commercial products available
under the TINUVIN trade name (BASF).
The thermoplastic film resin is generally melt blended with the
desired additives and then formed into pellets. Masterbatches of
resin and additives may be employed.
The thermoplastic film in total is from about 1 mil to about 12
mils thick.
In the 2 layer system the side with the thermoplastic film is
intended to face the exterior and be exposed to weather, gravel,
etc.
In the 2 layer system, the thermoplastic film is preferably
aliphatic TPU. In the 3 layer system, the thermoplastic film is
preferably aromatic TPU, based on aromatic isocyanate
compounds.
It is mentioned above that the thermoplastic film may also be
formulated with flame retardants, light stabilizers, etc. The fiber
mats may also be formulated with these additives.
The present panel constructions may advantageously employ no
adhesive layers between components (a), (b) and (c).
As mentioned, forming of the fiber mat takes place for instance in
a heated, shaped tool to a desired shape, for instance a
compression tool. A fiber mat prepreg is placed in a hot molding
tool. The molten thermoplastic resin is then applied to the prepreg
for instance via injection molding. The tool may then be closed by
hydraulic press to compress the 2 layers into a sturdy composite. A
scrim may be used between the thermoplastic film and tool surface
as required.
Alternatively, a thermoplastic resin may be coextruded with a
release liner to form a film. The thermoplastic film is applied to
a surface of a fiber mat with heat and pressure. The thermoplastic
film is from about 1 mil to about 12 mils thick while the release
liner is about 1 mil thick. This construction may be formed in a
heated, shaped tool. The release liner will have poor adhesion to
the thermoplastic film and after thermoforming the release liner
can be separated from the tool and the thermoplastic film. The
release liner may be for instance a polyolefin while the
thermoplastic film is for instance TPU.
In the 3 layer system, a second fiber mat is applied on the
thermoplastic film layer. The hot tool is closed by hydraulic press
to compress the 3 layers into a sturdy composite. In the 3-layer
system, the thermoplastic film may reside essentially completely
within the adjacent surfaces of the fiber mats or up to about 40%
of the thermoplastic film may reside between the fiber mats as a
discrete layer.
Other advantages of the present constructions are that they are
mechanically stable, are seamless panels, may employ a variety of
colors via incorporation of pigments, are field repairable with
auto body techniques, have good thermal shock resistance, have high
strength/low weight, have easy handling and mobility, reduce
production steps, have high sound damping, are weather and moisture
resistant and are non-permeable.
The panel constructions are suitable for a lower sound shield,
acoustical belly pan, aero shield, splash shield, underbody panel,
chassis shield, wheel well liners and the like. The present panels
reduce wind drag, improve mileage performance, reduce engine noise
and prevent excessive water or snow intrusion into the engine
compartment.
Additional layers, such as a foam layer, may also be part of the
panel constructions. In the 3 layer system, the foam layer would be
attached and cover one or both faces of the fiber mats. In the 2
layer system, the foam layer would be attached and cover the face
of the fiber mat while the thermoplastic film covers the other face
of the fiber mat. The foam layer may comprise those known such as
polyurethane, polyisocyanate or a mixture thereof. The foam layer
may be applied to the fiber mat with an adhesive layer.
Specifically, the following embodiments are disclosed.
Embodiment 1
A panel construction suitable as an automobile part, comprising
(a) a first composite fiber mat layer and
(b) adjacent to and covering a face of the fiber mat, a
thermoplastic polymer film, and optionally
(c) adjacent to and covering the thermoplastic film, a second
composite fiber mat layer,
where the composite fiber mat comprises fibers or fabrics and a
cured acrylic resin binder.
Embodiment 2
A panel construction according to embodiment 1, where the
thermoplastic film is a polyvinylchloride, polyethylene, polyester,
polyetheretherketone, or a polyurethane film.
Embodiment 3
A panel construction according to embodiment 1, where the
thermoplastic film is a thermoplastic polyurethane film.
Embodiment 4
A panel construction according to embodiments 1, 2 or 3, where the
fiber mat a) comprises non-woven cellulosic bast fibers, non-woven
polyester fibers or glass fibers and the acrylic resin is from
about 15% to about 50% by weight dry resin, based on the weight of
the fiber mat.
Embodiment 5
A panel construction according to any of the preceding embodiments,
where the thermoplastic polymer film comprises one or more
additives selected from the group consisting of pigments, dyes,
flame retardants, hindered amine light stabilizers, ultraviolet
light absorbers and anti-static agents.
Embodiment 6
A panel construction according to any of the preceding embodiments,
which construction contains no adhesive layers between components
(a), (b) and (c).
Embodiment 7
A panel construction according to any of the preceding embodiments,
where the fiber mats are from about 1.5 to about 2 mm thick.
Embodiment 8
A panel construction according to any of the preceding embodiments,
where the thermoplastic film in total is from about 1 mil to about
12 mils thick.
Embodiment 9
A panel construction according to any of the preceding embodiments,
which is a 3 layer system comprising components (a), (b) and
(c).
Embodiment 10
A panel construction according to embodiment 9, where the two fiber
mats are identical.
Embodiment 11
A panel construction according to embodiment 9, where the two fiber
mats are not identical.
Embodiment 12
A panel construction according to any of embodiments 1 to 8, where
a portion of the thermoplastic polymer film resides beneath the
surface of the first fiber mat.
Embodiment 13
An automotive part comprising the panel construction according to
any of the preceding embodiments.
Embodiment 14
The automotive part according to embodiment 13, wherein the
automotive part is a lower sound shield, acoustical belly pan, aero
shield, splash shield, underbody panel, chassis shield or a wheel
well liner.
Example
Wheel or Underbody Shield Liners
A mixture of an aqueous based acrylic binder, ACRODUR, is applied
to a non-woven glass/PET fiber matrix. The acrylic resin content is
30% by weight, dry weight of resin based on the total weight of the
mat. This is a fiber mat prepreg.
The first fiber mat prepreg layer of a wheel liner with a dry
weight of 1200 grams/m.sup.2 is placed on a hot molding tool. A
molten thermoplastic polyurethane resin, ELASTOLLAN 1160D10, is
then applied to the shaped fiber mat to form a film. A second fiber
mat prepreg with a dry basis weight of 500 grams/m.sup.2 is then
laid on the thermoplastic film layer. The hot tool is closed by
hydraulic press compressing the 3 layers into a sturdy composite
structure formed to the shape of the molding tool, in this case a
wheel liner. About 40% of the thermoplastic film resides beneath
the surface of the first fiber mat and about 30% of the
thermoplastic film resides beneath the surface of the second fiber
mat. The remaining 30% of the thermoplastic film is a discrete
thermoplastic layer between the fiber mats.
* * * * *